Process for electroforming nickel foils

Claim 2

In a method of electroforming a smooth surface of nickel cobalt or alloy thereof on a conductive substrate from which it may subsequently be removed from a nickel sulfamate electroforming solution, the improvement comprising increasing the current density from zero at an average rate of between about 75 to 600 ASF per minute over the first 2 to 20 percent of the plating cycle to an ultimate current density of between about 200 and about 600 ASF, and the ultimate current concentration is between about 5 and about 15 amperes per gallon of electroforming solution.

Claim 3

The method of claim 1 wherein the current density is increased at an average rate of between about 100 and about 400 ASF per minute to the ultimate current density.

Claim 4

The method of claim 1 wherein the electrolyte contains total nickel of from about 12 to about 15 oz/gal.

Claim 5

The method of claim 1 wherein the amount of total nickel constitutes from about 13.5 to about 14 oz/gal.

Claim 6

The method of claim 1 in which the electrolyte contains nickel and chloride as NiCl 2 .6H 2 O and the ratio of chloride as NiCl 2 .6H 2 O to total nickel is from about 0.10 to about 0.14.

Claim 7

The method of claim 1 in which the electrolyte contains nickel and bromide.

Claim 8

The method of claim 1 wherein the current density is initially maintained at less than about 50 percent of its ultimate amperage for a period of up to 15 percent of the total plating time.

Claim 9

The method of claim 1 wherein the current density is initially maintained at less than about 50 percent of its ultimate amperage for a period of up to 5 to 15 percent of the total plating time.

Claim 10

The method of claim 1 wherein the current density is initially maintained at less than about 25 percent of its ultimate amperage for a period of up to 5 to 15 percent of the total plating time.

Claim 11

The method of claim 1 wherein the ultimate current density is between about 250 and about 350 ASF, and the current density is maintained within about 5 percent of its ultimate current density during the second half of the plating period.

Claim 12

The method of claim 1 wherein the current density is from 5 to 150 ASF over the first 15 seconds of the plating cycle.

Claim 13

The method of claim 1 wherein the current density is from 5 to 150 ASF over the first 30 seconds of the plating cycle.

Claim 14

The method of claim 1 in which the conductive substrate is cylindrical and is rotated within a conforming cylindrical anode

Claim 15

The method of claim 13 in which the cylinder is rotated to maintain a turbulent flow near the cathode surface.

Claim 16

The method of claim 1 wherein the current is raised from 0 to 300 ASF during the first 120 seconds of the plating cycle.

Claim 17

The method of claim 1 wherein the conductive substrate is comprised of an aluminum cylinder having a smooth, chromium surface.

Claim 18

The method of claim 1 wherein the nickel foil formed is between 0.004 and 0.006 inches thick.

Claim 19

The method of claim 1 wherein the conductive substrate is comprised of an aluminum cylinder having a smooth chromium surface and is from about 4 inches in diameter to about 30 inches in diameter.

Claim 20

In a method of electroforming a smooth surface of nickel on a conductive substrate from which it may subsequently be removed from a nickel sulfamate electroforming solution, of 10 to 16 oz/gal total nickel, 0.9 to 4.5 oz/gal halide as NiX 2 .6H 2 O and 4.5 to 6.0 oz/gal H 3 BO 3 , at a temperature of between about 140°F and about 160°F, the improvement comprising increasing the current density from zero at an average rate of between about 75 and 600 ASF per minute over the first 2 to 50 percent of the plating cycle to an ultimate current density of between about 200 and about 600 ASF, and the ultimate current concentration is between about 5 and about 15 amperes per gallon of electroforming solution.

Claim 21

In a method of electroforming a smooth surface of nickel on a conductive substrate from which it may subsequently be removed from a nickel sulfamate electroforming solution, of 10 to 16 oz/gal total nickel, 0.9 to 4.5 oz/gal halide as NiX 2 .6H 2 O and 4.5 to 6.0 oz/gal H 3 BO 3 , at a temperature of between about 140°F and about 160°F, the improvement comprising increasing the current density from zero at an average rate of between about 75 and 600 ASF per minute over the first 2 to 50 percent of the plating cycle to an ultimate current density of between about 200 and about 600 ASF, and the ultimate current concentration is between about 5 and about 15 amperes per gallon of electroforming solution.

Claim 22

The method of claim 19 wherein the current density is increased at an average rate of between about 100 and about 400 ASF per minute to the ultimate current density.